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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 737 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions - On Vehicle >> Cylinder Sleeve Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the piston and connecting rod. Refer to Piston, Connecting Rod, and Bearing Replacement .
  2. Inspect the condition of the piston. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection .
    3. NOTE: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve.
    NOTE: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur.
    Fig 1: View Of Cylinder Bore Sleeve Puller
    GM1333588Courtesy of GENERAL MOTORS CORP.
  3. Rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
  4. Install the cylinder bore sleeve puller EN 45680-852 (1) through the cylinder bore.
    5. NOTE: Ensure that the shoe is flat against the bottom of the cylinder bore liner or damage to the cylinder bore liner puller EN45680-852 will occur.
  5. Align the shoe (1) of the cylinder bore sleeve puller EN 45680-852 to the bottom of the cylinder bore sleeve (2).
    6. Fig 2: Aligning Cylinder Bore Sleeve Puller
    GM1253939Courtesy of GENERAL MOTORS CORP.
  6. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-852 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
  7. Install the fixture EN 456850-851 (4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-852 and the engine block.
  8. Install the bearing (3) and the nut (1).
  9. Tighten the nut (1) to the bearing (3).
    10. NOTE: Refer to Fastener Notice .
    IMPORTANT: Use four old cylinder head bolts for the attaching bolts.
  10. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block.

    Tighten:  Tighten the bolts to 15 N.m (11 lb ft).

    11. Fig 3: Rotating Nut Clockwise To Remove Cylinder Bore Sleeve
    GM1333489Courtesy of GENERAL MOTORS CORP.
  11. Rotate the nut clockwise in order to remove the cylinder bore sleeve.
    12. Fig 4: Cylinder Bore Sleeve
    GM1333497Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure.
  12. Remove fixture EN 45680-851, cylinder bore liner sleeve EN 45680-852, and the cylinder bore liner from the engine block.
  13. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
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